Lens with elongated radiation pattern

ABSTRACT

A lens comprises an elongated shape. The lens has a short axis and a long axis. The lens comprises an upper surface through which a substantial majority of light exits the lens when a light emitting element is situated at or below a base of the lens. The upper surface includes a trough that extends along at least one of the short and the long axis. The upper surface includes a surface of a curved wall that joins the upper surface to the base of the lens. A lower surface of the trough is curved along the short axis and along the long axis. The lower surface of the trough has a curvature along the short axis that differs from a curvature along the long axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/579,105, filed Dec. 21, 2017, which is the U.S. National Stage, under35 U.S.C. § 371, of International Application No. PCT/US2016/033457,filed May 20, 2016, which claims the benefit of U.S. ProvisionalApplication No. 62/169,053, filed Jun. 1, 2015, the contents of whichare hereby incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates to the field of light emitting devices, and inparticular to a lens structure that facilitates the generation of anelongated radiation pattern.

BACKGROUND OF THE INVENTION

Lenses are commonly used to alter the shape of theillumination/radiation pattern produced by a light source. Elongatedillumination patterns are often required for camera flash lamps, vehiclehead lamps, street lighting, and so on.

U.S. Pat. No. 7,339,200, “LIGHT-EMITTING DIODE ANTI VEHICULAR LAMP”,issued 4 Mar. 2008 to Amano et al. discloses a lens that provides anelongated illumination pattern for a vehicular lamp by increasing thedivergence of light from a light emitting device along one axis. Tocompensate for the greater intensity of light when viewed from thecenter of the light emitting source, compared to the off-centerintensity, the lens includes a concave portion about an optical centerof the light emitting device, and a convex portion on either side of theoptical center, the convex portions having a larger emission surfacethan the concave portion. The resultant lens is “peanut shaped”, theconcave portion corresponding to the narrowed center portion of a peanutshell.

FIGS. 1A-1D illustrate an example peanut shaped lens 100 that providesan elongated illumination pattern from a single light source that emitsa Lambertian radiation pattern. FIG. 1A is a perspective view thatillustrates the peanut shape having a narrowed center region 110separating two larger lobes 120. The illustrations are not to scale, andmay include exaggerated features for ease of illustration andexplanation. In some embodiments, the difference in size/volume betweenthe larger lobes 120 and the smaller center region 110 may besubstantially less than illustrated in these figures.

FIG. 1B illustrates a top view of the peanut shaped lens of FIG. 1A,while FIGS. 1C and 1D illustrate cross-section views taken along viewsC-C and D-D, respectively, of FIG. 1B. The view C-C is taken along thelong axis 130, and the view D-D is taken along the short axis 140. Asillustrated in FIG. 1C, the larger lobes 120 form a convex surface, andthe center region 110 forms a concave structure, as viewed alongcross-section C-C. As illustrated in FIG. 1D, the cross-section of thecenter region 110 forms a convex surface. This convex cross-sectionextends for the entire length of the lens through the long axis 130 ofthe lens, include the larger lobes 120, the radius of the convex surfacechanging accordingly. Light source 150 may be a semiconductor lightemitting device (LED), or a plurality of light emitting devices, and maybe arranged within a recess of the lens or situated on or near the lowersurface of the lens.

FIGS. 2A and 2B illustrate the light propagation through the lens 100with respect to each axis 130, 140, respectively. As disclosed, the lens100 includes a concave lens portion 210 and two convex lens portions 220on either side of the concave lens 210. Each of these lens portionsprovide an optical axis with respect to the light source 150. Theconcave lens portion 210 provides optical axis 201, and each of theconvex lens portions 220 provides an optical axis 202. Each optical axis202 extends from the light source 150 through the center of curvature205 of the convex lens portion 220. The concave lens 210 serves todisperse the light emitted from the light source 150 away from theoptical axis 201, forming an elongated light emission pattern along thelong axis 130. Each of the convex lenses 220 serve to converge the lighttoward its respective optical axis 202, which results in an elongatedlight emission pattern along the long axis 130. By proper selection ofthe size and curvatures of the lenses 210, 220, a uniformly illuminatedelongated light emission pattern may be formed.

The cross section of the lens 100 relative to the short axis 140 forms aconvex lens 240. The cross section taken along any point on the longaxis 130 forms a similarly shaped convex lens, as indicated by thedashed line 240′, the size being relative to the height and width of thelens 100 along the long axis 130. As illustrated, the convex lens 240serves to concentrate/collimate the light from the light source 150,forming a relatively narrow light emission pattern along the short axis140. The convex lens 240′ will similarly concentrate/collimate the lightfrom the light source 150, maintaining a narrower light emission patternalong the short axis 140.

The overall emission pattern formed by the lens 100 is long in one axis,and narrow in the other axis, forming a substantially rectangular, oroval illumination pattern. However, the complex shape of the lens 100introduces interdependencies between the parameters in each dimension.For example, if a wider illumination pattern is desired relative to theshort axis (FIG. 2B), the radius of curvature of the convex lens 240 mayneed to be decreased. This change of shape of the lens 240 may limit thefeasible shapes of the lenses 220. Constraints on the physical size ofthe lens as well as methods of forming a suitable mold may also limitthe shape of the lens.

SUMMARY OF THE INVENTION

It would be advantageous to provide a lens that provides an elongatedillumination pattern that allows for greater independence with regard tothe shape of the illumination pattern in each axis. It would beadvantageous, for example, to provide a lens that provides asubstantially rectangular or oval illumination pattern with greaterindependence of control of each dimension of the rectangle/oval.

To better address one or more of these concerns, in an embodiment ofthis invention, an elongated lens is formed with an elongated troughalong the long axis on the light emitting surface of the lens. Theelongated lens may include a curved wall about its perimeter, and asmooth transition between the curved wall and the trough. The trough mayinclude a concave shape along both the long axis and the short axis,although the radius of curvature of the concave shape may differ betweenthe long and short axes. The eccentricity of the illumination patternmay b e controlled by the size of the trough and these radii ofcurvature.

A light emitting device may be formed by providing a light emittingelement and an elongated lens having a short axis, a long axis, and anupper surface through which desired light from the light emittingelement is emitted; wherein the upper surface of the lens includes atrough that extends along the long axis, and a perimeter of the lensincludes a curved wall.

The trough may be symmetric about the short axis and/or the long axiswith respect to an optical axis of the light emitting element There maybe a smooth transition joining the trough to the curved wall, and atleast a portion of the curved wall may be reflective.

The lower surface of the trough may have a curvature along the shortaxis that differs from a curvature along the long axis, and may have aperimeter that is substantially oval. In like manner, the perimeter ofthe lens may b e substantially oval. The oval perimeter may also betruncated in the long or short dimension.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in further detail, and by way of example,with reference to the accompanying drawings wherein:

FIGS. 1A-1D illustrate an example prior art light emitting device thatincludes an elongated lens that provides a substantially rectangular oroval illumination pattern.

FIGS. 2A-2B illustrate the cross-section of the light emitting device ofFIGS. 1A-1D, with representative light rays.

FIGS. 3A-3D illustrate an example light emitting device that includes anelongated lens in accordance with aspects of this invention.

FIGS. 4A-4B illustrate the cross sections of the light emitting deviceof FIGS. 3A-3D, with representative light rays.

FIGS. 5A-5D illustrate another example light emitting device thatincludes an elongated lens in accordance with aspects of this invention.

FIGS. 6A, 6B, 7A, 7B, 8, and 9 illustrate other example elongated lensesin accordance with aspects of this invention.

Throughout the drawings, the same reference numerals indicate similar orcorresponding features or functions. The drawings are included forillustrative purposes and are not intended to limit the scope of theinvention.

DETAILED DESCRIPTION

In the following description, for purposes of explanation rather thanlimitation, specific details are set forth such as the particulararchitecture, interfaces, techniques, etc., in order to provide athorough understanding of the concepts of the invention. However, itwill be apparent to those skilled in the art that the present inventionmay be practiced in other embodiments, which depart from these specificdetails. In like manner, the text of this description is directed to theexample embodiments as illustrated in the figures, and is not intendedto limit the claimed invention beyond the limits expressly included inthe claims. For purposes of simplicity and clarity, detaileddescriptions of well-known devices, circuits, and methods are omitted soas not to obscure the description of the present invention withunnecessary detail.

For ease of explanation and understanding, directions and/ororientations are specified with reference to a “top-emitting” lightemitting device, wherein, for example, light is assumed to propagate‘up’ from a light source then exit from an “upper surface” of the lens,opposite the location of the light source. Typically the light sourcewill be a parallelepiped where two of the surfaces will be larger thanthe other four. One of the larger surfaces is designated as the “top” ofthe light emitting device. The four smaller surfaces are the “sidesurfaces” of the light emitting device which typically emit little or nolight. Most of the light is emitted from the “top” of the light emittingdevice. The “upper surface” of the lens is opposite the “top” of thelight emitting device.

Some light may exit the ‘side surfaces’ of the lens i.e. the portions ofthe lens opposite the “side surfaces” of the light emitting device. Thelens of this invention is designed such that a substantial majority ofthe light from the light source exits the upper surface, in contrast tolenses that are designed to create side-emitting devices that emit asubstantial majority of the light through surfaces that are not directlyopposite the light source.

FIGS. 3A-3D illustrate an example light emitting device that includes alight source 350, and an elongated lens in accordance with aspects ofthis invention. The light source 350 may include a single light emittingelement, such as a light emitting diode, or multiple light emittingelements.

In any of the described embodiment the lens may be made of epoxy,silicone, sol-gel, glass or compounds, mixtures, or hybrids thereof. Theindex of refraction at the wavelength of the light source may range from1.4 to 2.2. High index nano-particles with particle sizes less than 100nm and preferably less than 50 nm dispersed in silicone or a silicatebinder may be used to enhance or tune the index of refraction of thelens. Details of the materials can be found in US publication number20110062469, which is commonly assigned and incorporated by reference inits entirety.

In one embodiment the light source may be a light emitting diode (LED)with a dimension ranging from 0.2 to 6 mm. The lens may have an outsidedimension ranging from 1.5 to 50 times the dimension of the LED. Theaspect ratio of the long to short dimension of the lens can range from1.25 to 50.

FIG. 3A illustrates a perspective view of the elongated lens 300. FIG.3B illustrates a top view of the elongated lens 300, through which lightis emitted. FIG. 3C illustrates a cross section view C-C taken along thelong axis 330. FIG. 3D illustrates a cross section view D-D taken alongthe short axis 340. The perimeter 305 of the lens 300 is an oval shapewith long and short dimensions. The perimeter 305 has curved ends alongthe short dimension and straight lines along the long dimension. In thealternative, the straight lines may have a convex curvature so as toform, for example, an elliptical perimeter.

As illustrated, the lens 300 includes a trough 310 formed in the uppersurface 320. For the purposes of this disclosure, a trough is defined asa depression in the upper surface 320, along an axis of the lens 300that is shorter than the length of the lens along that axis. The trough310 may have an oval shape with a long dimension and a short dimension.The ratio of the dimension of the trough may be the same or differentthan the ratio of the long and short dimensions of the lens 300, and theperimeter 315 of the trough 310 may be similar in shape to the perimeter305 of the lens 300. As detailed further below, to provide a continuousdispersion of the light emitted from the light source 350, the perimeter305 of the lens 300 may include a curved wall 325, and there may be asmooth transition 317 between the curved wall 325 and the trough 310.Similarly, the trough 310 may include curved surfaces 316. For ease ofexplanation and understanding the term “upper surface 320” is usedherein to refer to the surface of trough 310, the surface of curvedportions 316 and 317, and the surface of the curved portion of thecurved wall 325, collectively the surface of the lens 300 emitting thedesired light.

The lens 300 includes a base 326, which may include a recess forreceiving the light source 350; alternatively, the light source 350 maybe flush with the base or slightly below the base 326. Light source 350may include a reflector, a reflector cup, or a reflector ring.

One of skill in the art will recognize that discontinuous surfaces maybe used, but in general, a smooth continuous surface is preferred toprovide an illumination pattern that does not include abrupt transitionsin illumination intensity. However, if abrupt transitions are desirable,discontinuous surfaces may provide the desired illumination pattern. Thelens 300 may be formed via a mold that provides the shapes of the lens300, including the trough 310. Other techniques for forming the lens 300are feasible, including milling the trough 310 out of a preformedelongated lens.

As illustrated in FIGS. 3C and 3D, the trough 310 introduces a lowerelevation of the lens 300 at or near the optical axis 301, and a higherelevation on the upper surface 320 of the lens 300.

In the example cross-section C-C of: FIG. 3C, a lower surface 315 of thetrough 310 may be nearly flat near the optical axis 301, then curvesupward 316 toward the higher elevation of the upper surface 320. Thissubstantially flat region 315C may introduce more loss of the lightemitted by the light source 350 than a more sharply shaped convexregion. Light striking the flatter region 315C of the depression 310 atgreater than a critical angle will be totally internally reflected (TIR)away from the region 315C, thereby increasing the likelihood of thelight being absorbed in the device.

In the example cross-section D-D of FIG. 3D, the lower surface 315 ofthe trough 310 along the short axis 340 provides a concave shape 315D,which also disperses light from the light source 350, but not as farspatially because the convex lobes 320 are more closely spaced along theshort axis 340 than for the long axis 330.

The degree of dispersion of the light in the center region of the lens300 is determined by the shape (length, width, depth, shape) of thetrough 310, including the radius of curvature of the lower surface 315along each axis 330, 340. The surface 315 along the cross-section C-Cincludes three radii of curvature, a radius of curvature for each of thecurved portions 316, and a radius of curvature for the center portion315C, which may be very large. The surface 315 along the cross sectionD-D includes the radius of curvature of concave portion 315D. In thisexample, the degree of dispersion will be greater along the long axis330, and the total internal reflection at the surfaces 316 may augmentthe illumination intensity at angles farther from the optical axis 301.

FIGS. 4A-4B illustrate the propagation of light through the lens 300relative to the long axis 330 and short axis 340, respectively.

As illustrated in FIG. 4A, the cross section shape along the long axis330 comprises a concave lens 410A and two convex lens portions 420. Theconcave lens portion 410A will disperse the light away from the opticalaxis 401, albeit to a lesser extent than it would if the convex lensportions 420 were more widely spaced apart The two convex lens portions420 converge the light toward their corresponding optical axes 402.

The overall effect of the lens portions 410A, 420 is an elongation ofthe illumination pattern along the long axis 330. The extent of theelongation may be controlled by the orientation of the optical axes 402,the centers of curvature 405, as well as the radii of curvature for eachof the lens portions 410A, 420, and other parameters related to theshape of the profile along the long axis 330.

As illustrated in FIG. 4B, the cross section shape along the short axis340 comprises a concave lens portion 410B and two convex lens portions440. Of particular note, although both the concave lens portion 410A(FIG. 4A) and the concave lens portion 410B are formed by the trough 310(FIG. 3), the shape of each lens portion 410A, 410B are substantiallyindependent of each other. In this example, lens portion 410A is flatterthan lens portion 410B, which is continually curved.

In like manner, the two convex lens portions 440 of FIG. 4B may differsubstantially from the convex lens portions 420 of FIG. 4A. Although inthis example, the lens portions 440 and 420 are somewhat similar, one ofskill in the art will recognize that the surface 320 (FIG. 3) that formsthese lens portions 420, 440 need not be uniformly thick around the lens300, nor uniformly tall. One of skill in the art will recognize thatillumination analysis programs may be used to determine the appropriateshape for transitioning between such differing shapes.

As in FIG. 4A, the extent and uniformity of the illumination patternrelative to the short axis 340 may be controlled by the orientation ofthe optical axes 404 of the convex lens portions 440, the centers ofcurvature 407 of these lenses 440, as well as the radii of curvature foreach of the lenses 410B, 440, and other parameters related to the shapeof the profile along the short axis 340.

One of skill in the art will recognize that the particular shape of thetrough, as well as the overall shape of the lens, will be based on thedesired light illumination pattern, as well as the intensitydistribution. In some embodiments, for example, it may be desirable toprovide uniform intensity near the center of the illumination pattern,tapering off, gradually or more sharply, at a given off-axis angle ineach dimension. Conventional light propagation and illumination analysistools may be used to determine a combination of shapes in each dimensionthat produces the desired illumination pattern and intensitydistribution.

FIGS. 5A-5D illustrate another example light emitting device thatincludes an elongated lens in accordance with aspects of this invention.As contrast to the lens 300, which includes a substantially ovalperimeter and substantially oval trough 310, the lens 500 of FIGS. 5A-5Dincludes a substantially elliptical profile and substantially ellipticaltrough 510.

For the purposes of this disclosure, the term oval is used to describean elongated shape having a curved perimeter, including elliptical orother shapes. For ease of explanation and understanding the term “uppersurface 520” is used herein to refer to the surface of trough 510, thesurface of curved portion 517, and the surface of the curved portion ofthe curved wall 525, collectively the surface of the lens radiating thedesired light.

As illustrated, the curved wall 525, having no linear portions, forms asubstantially elliptical perimeter of the lens 500, and the trough 510also has substantially elliptical perimeter. In this example, the lowersurface 515 provides a substantially continuous concave profile 515C inthe long axis 530, and a substantially continuous concave profile 515Din the short axis 540. The profile 515C along the long axis 530 maycorrespondingly provide a more disperse emission pattern from the centerof the lens 500 with less loss than the flatter profile 315C of lens300. One of skill in the art will recognize, however, that portions ofthe lower surface 515, in either axis, may be less curved, to increasethe intensity of light at the center of the lens 500.

As noted above, conventional light propagation analysis tools may beused to determine the shape of the lens, the shape of the trough, theradii of curvature within the trough, as well as the radius of curvatureof the curved wall 525, and the radii of curvature forming the smoothtransition between the curved wall 525 and the trough 510.

FIGS. 6-9 illustrate other example elongated lenses with troughs inaccordance with aspects of this invention. Each of these example lensesinclude features that augment the light emission pattern produced by thelenses conforming to those (300, 500) of FIGS. 3A-3D and FIGS. 5A-5D, aswell as other shapes conforming to the principles of this disclosure.These features may serve to provide a more uniform light distribution,for example, by further dispersing light emitted from areas that mightotherwise form “bright regions”, or “dark regions” on a lens withoutthese features. One of skill in the art will recognize that fewer ormore features, in different sizes and shapes than illustrated may beused to achieve a desired illumination pattern.

The dimensions of each feature, including its radius of curvature, itsposition and orientation on the main body of the lens, and thecharacteristics of the main body of the lens itself will determine howthese features may affect the illumination pattern provided by the lenswith these features. In each embodiment, conventionalcomputer-aided-design tools, and/or light propagation analysis tools maybe used to determine the effect that the shape and dimensions of eachaugmentation/feature will have on the resultant light emission patternproduced by the lenses.

In FIGS. 6A-6B, the features 680 are added to a lens 600 that includes atrough 610 that has a perimeter 615 that is similar in shape to theperimeter 605 of the lens 600; and in FIGS. 7A-7B, the features 780 areadded to a lens 700 that has a trough 710 that has a perimeter 715 thatis different in shape from the perimeter 705 of the lens 700.

In these examples, the lens 700 includes a trough 710 that is shorterand deeper that the trough 610 of lens 600, such that it affects theprofile of the lens, as illustrated in FIG. 7B, serving to illustratethat the particular arrangement of the trough with respect to the mainbody of the lens may vary, depending upon the desired illuminationpattern. Features 680 and 780 may be convex dimples, each having asurface that is a portion of the surface of sphere or the surface of anellipse.

In FIG. 8, a convex feature 880 is added at the center of the trough 810of lens 800, and in FIG. 9, a concave feature (dimple) 980 is added atthe center of the trough 910 of lens 900. One of skill in the art willrecognize that the features 880 or 980 may be a flat surface as well.Features 880 and 980 may each have a surface that is a portion of thesurface of sphere or the surface of an ellipse.

In each of the FIGS. 6-9, the features are illustrated as having sharpedges where they intersect the main body of the lens; one of skill inthe art will recognize, however, that a smooth transition from the mainbody to each feature may provide for a more uniform illuminationpattern.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, such illustration and descriptionare to be considered illustrative or exemplary and not restrictive; theinvention is not limited to the disclosed embodiments.

For example, it is possible to operate the invention in an embodimentwherein the lower surface of the lens as well as the upright portions ofthe curved wall are reflective, thereby reducing absorption lossesand/or light propagation in unwanted directions. The transition betweenthe convex and concave regions of the lens (e.g. 316 of lens 300 in FIG.3C) may also be reflective, to augment the total internal reflection(TIR) in these regions. The concave region may also be entirely orpartially coated with reflective material to increase total internalreflection.

Other variations to the disclosed embodiments can be understood andeffected by those skilled in the art in practicing the claimedinvention, from a study of the drawings, the disclosure, and theappended claims. In the claims, the word “comprising” does not excludeother elements or steps, and the indefinite article “a” or “an” does notexclude a plurality. Any reference signs in the claims should not beconstrued as limiting the scope.

What is claimed is:
 1. A lens comprising: an elongated shape, the lenshaving a short axis and a long axis; and an upper surface through whicha substantial majority of light exits the lens when a light emittingelement is situated at or below a base of the lens; wherein the uppersurface includes a trough that extends along at least one of the shortand the long axis.
 2. The lens of claim 1, wherein the upper surfaceincludes a surface of a curved wall that joins the upper surface to thebase of the lens.
 3. The lens of claim 1, wherein a lower surface of thetrough is curved along the short axis and along the long axis.
 4. Thelens of claim 3, wherein the lower surface of the trough has a curvaturealong the short axis that differs from a curvature along the long axis.5. The lens of claim 1, further comprising a recessed portion thatintersects a periphery of the trough.
 6. The lens of claim 1, furthercomprising one of a raised portion and a recessed portion within thetrough.